Aerodynamic noise reduction cage

ABSTRACT

A control valve has a body having an inlet and outlet, a valve seat between the inlet and outlet, a valve plug, and a cage adjacent the valve seat to provide guidance for the valve plug. The valve plug is movable between a closed position, where the valve plug sealingly engages the valve seat, and an open position, where the valve plug is spaced away from the valve seat. The cage has a circumferential wall having inner and outer surfaces and a plurality of passages formed through the wall. Each passage can have a first portion extending from the inner surface and a second portion extending from the outer surface, where the second portion has a diameter smaller than that of the first portion, can follow a non-linear path from the inner to outer surface, and/or can have a cross-sectional area that varies from the inner to outer surface.

FIELD OF THE DISCLOSURE

This disclosure relates generally to control valves and, moreparticularly, aerodynamic noise reducing cages for control valves.

BACKGROUND

In typical control valves, a valve cage may provide guidance for a valveplug as the valve plug moves from a closed position in which the valveplug sealingly engages a valve seat to an open position in which thevalve plug is disposed away from the valve seat. When the valve is inthe open position, fluid flows from a valve inlet, passes through apassage between the valve seat and the valve plug, passes through thevalve cage, and exits through a valve outlet. In addition to guiding thevalve plug, a valve cage can also be used for additional functions, suchas noise reduction.

Referring to FIG. 1, a typical control valve 10 is shown. Control valve10 generally includes a valve body 12 having an inlet 14 and an outlet16 and a passageway 18 disposed between inlet 14 and outlet 16. A valveseat 24 is disposed in passageway 18 between inlet 14 and outlet 16 anda solid cage 22 is disposed within valve body 12 adjacent valve seat 24.A fluid control member, such as valve plug 26, is positioned within body12 and is disposed within cage 22. Valve plug 26 interacts with thevalve seat 24 to control fluid flow through the body 12, such that valveplug 26 sealingly engages valve seat 24 in a closed position and isspaced away from valve seat 24 in an open position. A stem 28 isconnected to valve plug 26 at one end and to an actuator 30 at anotherend. Actuator 30 controls movement of valve plug 26 within cage 22. Thecage 22 is positioned adjacent valve seat 24 and proximate valve plug 26to provide guidance for valve plug 26.

In some gas applications, cage 22 has a plurality of passages 20 formedthrough a circumferential wall of cage 22, which are used is to reducethe noise produced as the gas passes through cage 22. Passages 20 arespaced specifically such that the jets of gas that are produced as thegas exits passages 20 do not converge and produce aerodynamic noise.Cages 22 used in these types of gas applications are typically used in a“flow up” orientation (e.g., the gas enters the center of cage 22 andpasses from an inside surface to an outside surface of cage 22) and thespacing of passages 20 that is crucial to reduce the aerodynamic noiseis on the outer surface of cage 22. The spacing of passages 20 on theinner surface of cage 22 is also important, as this spacing is used tokeep sufficient space between passages 20 to not allow flow to passthrough more passages 20 than desired for accurate flow characteristicsthroughout the travel of valve plug 26.

For solid cages 22 used in gas applications where the process conditionsproduce aerodynamic noise as the medium flows through control valve 11,drilled holes through the circumferential wall of cage 22 are typicallyused to form passages 20. However, drilled hole cages are verycumbersome, time consuming, and costly to produce. Some drilled holecages may contain thousands of holes and the only real feasible way toproduce passages 20 was to drill them with a ⅛ inch drill bit.Acceptance criteria exists that allows a percentage of drill bits tobreak and be left in the cage and this process requires the use ofspecial drilling machines that have a high degree of accuracy.

In addition to the spacing of passages 20 on the outer surface of cage22, aerodynamic noise can also be reduced by providing a tortured, ornon-linear, flow path for passages 20 or to varying the cross-sectionaldiameter of passages 20 as they pass through the wall of cage 22.However, with a drilled holes through a solid cage 22, creating passages20 having a non-linear flow path or having a variable cross-sectionalarea is not possible.

In addition to the noise issues that can be encountered in some gasapplications, in some liquid applications, conditions can occur thatwill produce a condition where the liquid cavitates, which can causesevere damage to control valve 10. In order to reduce the cavitationthat can occur to the point that it does not damage control valve 10 orto direct it to an area that is less susceptible to cavitation damage,passages that decrease in diameter in the direction of fluid flow can beused.

However, using drilled holes and conventional manufacturing techniquesto create passages 20 in a solid cage 22 requires that the holes be stepdrilled from the outer surface of the cage, which limits these holes tohaving the larger diameter portion of passage 20 on the outer surface ofcage 22 and the smaller diameter portion of passage 20 on the innersurface of cage 22, since the larger diameter portion has to be drilledfrom the outside of cage 22. This limits these types of cages 22 toapplications using a “flow down” orientation (e.g., the fluid enterscage 22 from the outer surface and passes from the outside surface tothe inside surface of cage 22) so that the pressure drops can be reducedas the flow goes through the control valve 10 and then downstream. Theoverriding reason this is done in this manner is the ability to drillthe stepped holes from the outside of cage 22. As described above,drilling the number of holes required through the wall of cage 22 forthis type of application is very cumbersome, time consuming, and costlyto produce.

BRIEF SUMMARY OF THE DISCLOSURE

In accordance with one exemplary aspect of the present invention, acontrol valve comprises a body having an inlet and an outlet, a valveseat positioned in a passageway of the body between the inlet and theoutlet, a valve plug positioned within the body, and a cage disposedwithin the body adjacent the valve seat and proximate the valve plug toprovide guidance for the valve plug. The valve plug is movable between aclosed position, in which the valve plug sealingly engages the valveseat, and an open position, in which the valve plug is spaced away fromthe valve seat. The cage comprises a circumferential wall having aninner surface and an outer surface and a plurality of passages formedthrough the wall and extending between the inner surface and the outersurface. Each of the passages comprises a first portion and a secondportion, where the first portion of the passage extends from the innersurface of the wall and has a first diameter and the second portion ofthe passage extends from the outer surface of the wall and has a seconddiameter, smaller than the first diameter.

In accordance with another exemplary aspect of the present invention, acontrol valve comprises a body having an inlet and an outlet, a valveseat positioned in a passageway of the body between the inlet and theoutlet, a valve plug positioned within the body, and a cage disposedwithin the body adjacent the valve seat and proximate the valve plug toprovide guidance for the valve plug. The valve plug is movable between aclosed position, in which the valve plug sealingly engages the valveseat, and an open position, in which the valve plug is spaced away fromthe valve seat. The cage comprises a solid, unitary circumferential wallhaving an inner surface and an outer surface and a plurality of passagesformed through the wall and extending between the inner surface and theouter surface. Each of the passages follows a non-linear path from theinner surface to the outer surface.

In accordance with another exemplary aspect of the present invention, acontrol valve comprises a body having an inlet and an outlet, a valveseat positioned in a passageway of the body between the inlet and theoutlet, a valve plug positioned within the body, and a cage disposedwithin the body adjacent the valve seat and proximate the valve plug toprovide guidance for the valve plug. The valve plug is movable between aclosed position, in which the valve plug sealingly engages the valveseat, and an open position, in which the valve plug is spaced away fromthe valve seat. The cage comprises a solid, unitary circumferential wallhaving an inner surface and an outer surface and a plurality of passagesformed through the wall and extending between the inner surface and theouter surface. Each of the passages comprises a cross-sectional areathat varies in size from the inner surface to the outer surface.

In accordance with another exemplary aspect of the present invention, acage for a control valve comprises a circumferential wall having aninner surface and an outer surface and a plurality of passages formedradially through the wall from the inner surface to the outer surface.Each of the passages comprises a first portion and a second portion,where the first portion of the passage extends from the inner surface ofthe wall and has a first diameter and the second portion of the passageextends from the outer surface of the wall and has a second diameter,smaller than the first diameter.

In accordance with another exemplary aspect of the present invention, acage for a control valve comprises a solid, unitary circumferential wallhaving an inner surface and an outer surface and a plurality of passagesformed through the wall and extending between the inner surface and theouter surface. Each of the passages follows a non-linear path from theinner surface to the outer surface.

In accordance with another exemplary aspect of the present invention, acage for a control valve comprises a solid, unitary circumferential wallhaving an inner surface and an outer surface and a plurality of passagesformed through the wall and extending between the inner surface and theouter surface. Each of the passages comprises a cross-sectional areathat varies in size from the inner surface to the outer surface.

In further accordance with any one or more of the foregoing exemplaryaspects of the present invention, a control valve or cage for a controlvalve may further include, in any combination, any one or more of thefollowing preferred forms.

In one preferred form, the circumferential wall of the cage is solid.

In another preferred form, each of the passages comprises a non-circularcross-sectional area.

In another preferred form, the cross-sectional area is one of a square,a rectangle, a triangle, an oval, a stars, a polygon, and an irregularshape.

In another preferred form, a sealed cavity is formed in the wall of thecage.

In another preferred form, the non-linear path is one of an arcuatepath, a helical path, and a stair-stepped shaped path.

In another preferred form, each of the passages comprises across-sectional area that varies from the inner surface to the outersurface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of an example control valve;

FIG. 2A is a cross-sectional view of an example cage that can be usedwith the control valve of FIG. 1;

FIG. 2B is an enlarged portion of the indicated portion of FIG. 2A;

FIG. 3A is a side view of a second example cage that can be used withthe control valve of FIG. 1;

FIG. 3B is a perspective view of the example cage of FIG. 3A with aportion removed to expose the passages;

FIG. 3C is a top cross-sectional view of the cage of FIG. 3A taken alongthe line C-C in FIG. 3A;

FIG. 3D is a top cross-sectional view of the cage of FIG. 3A taken alongthe line D-D in FIG. 3A;

FIG. 4A is a side view of a third example cage that can be used with thecontrol valve of FIG. 1;

FIG. 4B is a top cross-sectional view of the cage of FIG. 4A taken alongthe line B-B in FIG. 4A;

FIG. 4C is a top cross-sectional view of the cage of FIG. 4A taken alongthe line C-C in FIG. 4A;

FIG. 5A is a side view of a fourth example cage that can be used withthe control valve of FIG. 1;

FIG. 5B is a top cross-sectional view of the cage of FIG. 5A taken alongthe line B-B in FIG. 5A;

FIG. 5C is a top cross-sectional view of the cage of FIG. 5A taken alongthe line C-C in FIG. 5A;

FIG. 6A is a side view of a fifth example cage that can be used with thecontrol valve of FIG. 1;

FIG. 6B is a top cross-sectional view of the cage of FIG. 6A taken alongthe line B-B in FIG. 6A;

FIG. 6C is a top cross-sectional view of the cage of FIG. 6A taken alongthe line C-C in FIG. 6A;

FIG. 7A is a side view of a sixth example cage that can be used with thecontrol valve of FIG. 1;

FIG. 7B is a top cross-sectional view of the cage of FIG. 7A taken alongthe line B-B in FIG. 7A;

FIG. 7C is a top cross-sectional view of the cage of FIG. 7A taken alongthe line C-C in FIG. 7A;

FIG. 8A is a side view of a seventh example cage that can be used withthe control valve of FIG. 1;

FIG. 8B is a perspective view of the example cage of FIG. 8A with aportion removed to expose the passages;

FIG. 8C is a top cross-sectional view of the cage of FIG. 8A taken alongthe line C-C in FIG. 8A;

FIG. 8D is a top cross-sectional view of the cage of FIG. 8A taken alongthe line D-D in FIG. 8A;

FIG. 9A is a side view of a eighth example cage that can be used withthe control valve of FIG. 1;

FIG. 9B is a top cross-sectional view of the cage of FIG. 9A taken alongthe line B-B in FIG. 9A;

FIG. 9C is a top cross-sectional view of the cage of FIG. 9A taken alongthe line C-C in FIG. 9A;

FIG. 10 is a perspective view of a ninth example cage that can be usedwith the control valve of FIG. 1, with the passages shown in phantom;

FIG. 11A is a perspective view of an example cage that can be used witha control valve having side to side fluid flow, with a portion removedto expose the passages; and

FIG. 11B is a top cross-sectional view of the cage of FIG. 11A takenalong the line B-B in FIG. 11A.

DETAILED DESCRIPTION

Referring to FIGS. 2A-2B, one example of a cage 100 is shown that can beused with the control valve 10 described above and shown in FIG. 1. Cage100 can be manufactured0 using Additive Manufacturing Technology, suchas direct metal laser sintering, full melt powder bed fusion, etc. Usingan Additive Manufacturing Technology process, the 3-dimensional designof cage 100 is divided into multiple layers, for example layersapproximately 20-50 microns thick. A powder bed, such as a powder basedmetal, is then laid down representing the first layer of the design anda laser or electron beam sinters together the design of the first layer.A second powder bed, representing the second layer of the design, isthen laid down over the first sintered layer and the second layer issintered together. This continues layer after layer to form thecompleted cage 100.

Using an Additive Manufacturing Technology process to manufacture cagesfor control valves allows the freedom to produce passages having variousshapes and geometries, and other feature described below, that are notpossible using current standard casting or drilling techniques. Forexample, as described above, cages used in liquid applications can bemanufactured having passages that decrease in diameter in the directionof fluid flow to reduce cavitation in the control valve. However, usingstandard manufacturing techniques, these cages were limited toapplications using a “flow down” orientation as the larger diameterportion of each passages could only be drilled/machined on the outersurface of the cage. However, as shown in FIGS. 2A-2B, cage 100 can nowbe manufactured having passages that decrease in diameter from the innersurface to the outer surface, allowing cage 100 to be used inapplications using a “flow up” orientation, which was not previouslypossible.

As shown in FIGS. 2A-2B, cage 100 generally includes a circumferentialwall 102 forming a hollow central bore 112, within which the valve plug26 will slide to control fluid flow through cage 100. Wall 102 defines afirst end 104, an opposing second end 106, an inner surface 108, and anopposing outer surface 110. Passages 114 are formed through wall 102,extend between inner surface 108 and outer surface 110, and each have afirst portion 116 and a second portion 118. Passages 114 can be used tocharacterized fluid flowing through cage 100 by, for example, reducingthe pressure of the fluid as it flows through passages 114. Firstportion 116 of each passage 114 extends from inner surface 108 partiallyinto wall 102 and has a first diameter D1, or cross-sectional area ifpassages 114 are not circular. Second portion 118 of each passage 114extends from outer surface 110 partially into wall 102 and a seconddiameter D2, or cross-sectional area if passages 114 are not circular,that is smaller than diameter D1 of first portion 116.

Having passages 114 decrease in diameter from inner surface 108 to outersurface 110, which was not possible using standard manufacturingmethods, means that cage 100 can now be used in liquid applications toreduce cavitation in control valves having a “flow up” orientation,which was not previously possible, and the design is not restricted froma manufacturing standpoint. This can be beneficial as some controlvalves perform better with increased capacity and control in the “flowup” orientation. In addition, having cages that can be in either “flowup” or “flow down” orientations allows piping flexibility to end usersfor any given application and provides more flexibility for more sealconfigurations, which can be flow direction dependent.

As described above, passages 114 can have a generally circularcross-sectional area with a longitudinal axis that is perpendicular tothe longitudinal axis of cage 100. However, passages can also have othernon-circular cross-sectional area, such as square, rectangle, triangle,oval, star, polygon, and irregular shapes. Furthermore, a sealed cavity120, such as a “lightning hole” or “weight saver” or manifold, can alsobe formed in wall 102 of cage 100, to reduce the weight of cage 100 andsave material, which was not possible using standard manufacturingtechniques. Even with one or more of the above described features, suchas passages 114 with decreasing diameter, passages 114 with non-circularcross sections, and/or sealed cavities 120 formed in wall 102 of cage100, using an Additive Manufacturing Technology, wall 102 can still be asolid, unitary structure.

Referring to FIGS. 3A-D, a second example of a cage 200 is shown thatcan be used with the control valve 10 described above and shown inFIG. 1. Cage 200 can also be manufactured using an AdditiveManufacturing Technology process described in detail above for cage 100.

As shown in FIGS. 3A-D, cage 200 generally includes a solid, unitarycircumferential wall 202 forming a hollow central bore 212, within whichthe valve plug 26 will slide to control fluid flow through cage 200.Wall 202 defines a first end 204, an opposing second end 206, an innersurface 208, and an opposing outer surface 210. Passages 214 are formedthrough wall 202 and extend between inner surface 208 and outer surface210. Passages 214 can be used to characterized fluid flowing throughcage 200 by, for example, reducing the pressure of the fluid as it flowsthrough passages 214 or providing a tortured flow path through wall 202to reduce the velocity of the fluid flowing through cage 200.

In the example shown in FIGS. 3A-D, passages 214 are arcuate and followa non-linear path from inner surface 208 to outer surface 210 of wall202. As can best be seen in FIGS. 3C-D, passages 214 at verticallyadjacent locations in cage 200 can curve in opposite directions, whichprovides a tortured flow path for the fluid passing through cage 200 anddirects the exhaust from each vertically adjacent passages in differentdirections to avoid convergence of the exhaust paths and avoid producingaerodynamic noise. In the example shown, passages 214 formed in thefirst row of passages (FIG. 3C) curve from right to left and passages214 formed in the second row of passages (FIG. 3D) curve from left toright. Rows of passages 214 will continue to alternate the direction ofcurvature so that each row of passages will exhaust in a directiondifferent that the adjacent rows.

As described above, passages 214 can have a generally circularcross-sectional area. However, passages 214 can also have othernon-circular cross-sectional areas, such as square, rectangle, triangle,oval, star, polygon, and irregular shapes. In addition, thecross-sectional area of passages 214 can vary from inner surface 208 toouter surface 210. For example, passages 214 can have a decreasingcross-sectional area from inner surface 208 to outer surface 210, anincreasing cross-section area from inner surface 208 to outer surface210, a cross-section area that fluctuates between increased anddecreases size, or a cross-sectional area that changes shape as itpasses from inner surface 208 to outer surface 210. Furthermore, asealed cavity 220, such as a “lightning hole” or “weight saver” ormanifold, can also be formed in wall 202 of cage 200, to reduce theweight of cage 200 and save material, which was not possible usingstandard manufacturing techniques.

FIGS. 4A-C illustrate a third example of a cage 300 that can be usedwith the control valve 10 described above and shown in FIG. 1. Cage 300can also be manufactured using an Additive Manufacturing Technologyprocess described in detail above for cage 100. Cage 300 is identical tocage 200 described above and uses the same reference numbers foridentical parts, except that the rows of passages have the oppositecurvature from those shown in cage 200. For example, first row ofarcuate, non-linear passages 314 (FIG. 4B) curve from left to right, thesecond row of passages (FIG. 4C) curve from right to left, and the rowsof passages 314 continue to alternate.

As described above, passages 314 can have a generally circularcross-sectional area. However, passages 314 can also have othernon-circular cross-sectional areas, such as square, rectangle, triangle,oval, star, polygon, and irregular shapes. In addition, thecross-sectional area of passages 314 can vary from inner surface 208 toouter surface 210. For example, passages 314 can have a decreasingcross-sectional area from inner surface 208 to outer surface 210, anincreasing cross-section area from inner surface 208 to outer surface210, a cross-section area that fluctuates between increased anddecreases size, or a cross-sectional area that changes shape as itpasses from inner surface 208 to outer surface 210.

FIGS. 5A-C illustrate a fourth example of a cage 400 that can be usedwith the control valve 10 described above and shown in FIG. 1. Cage 400can also be manufactured using an Additive Manufacturing Technologyprocess described in detail above for cage 100. Cage 400 is similar tocage 200 described above and uses the same reference numbers foridentical parts. The main difference is that in each row, passages 414alternate the direction of curvature from the horizontally adjacentpassage 414. In addition, each alternating vertical row of passagescurves has curvature opposite that of the vertically adjacent rows. Forexample, each arcuate, non-linear passage 414 in the first row (FIG. 5B)has the opposite curvature from its two horizontally adjacent passagesand each arcuate non-linear passage 414 in the second row (FIG. 5C) hasthe opposite curvature from its two horizontally adjacent passages andfrom passages 414 in vertically adjacent rows.

As described above, passages 414 can have a generally circularcross-sectional area. However, passages 414 can also have othernon-circular cross-sectional areas, such as square, rectangle, triangle,oval, star, polygon, and irregular shapes. In addition, thecross-sectional area of passages 414 can vary from inner surface 208 toouter surface 210. For example, passages 414 can have a decreasingcross-sectional area from inner surface 208 to outer surface 210, anincreasing cross-section area from inner surface 208 to outer surface210, a cross-section area that fluctuates between increased anddecreases size, or a cross-sectional area that changes shape as itpasses from inner surface 208 to outer surface 210.

FIGS. 6A-C and 7A-C illustrate fifth and sixth examples of cages 500,600 that can be used with the control valve 10 described above and shownin FIG. 1. Cages 500, 600 can also be manufactured using an AdditiveManufacturing Technology process described in detail above for cage 100.Cages 500, 600 are identical to cage 200 described above and use thesame reference numbers for identical parts, except that passages 514,614 have a more complicated curvature than passages 214 of cage 200. Forexample, cage 500 (FIGS. 6A-C) has arcuate, non-linear passages 514 inthe first row (FIG. 6B) that curve from right to left adjacent innersurface 208, curve left to right in the middle of wall 202, and curveright to left adjacent outer surface 210. Conversely, arcuate,non-linear passages 514 in the second row (FIG. 6C) curve from left toright adjacent inner surface 208, curve right to left in the middle ofwall 202, and curve left to right adjacent outer surface 210. Thearcuate, non-linear passages 614 of cage 600 (FIGS. 7A-C) have anS-shaped configuration. For example, passages 614 in the first row (FIG.7B) curve from right to left adjacent inner surface 208, curve left toright and back right to left in the middle of wall 202, and curve leftto right adjacent outer surface 210. Conversely, passages 614 in thesecond row (FIG. 7C) curve from left to right adjacent inner surface208, curve right to left and back left to right in the middle of wall202, and curve right to left adjacent outer surface 210.

As described above, passages 514, 614 can have a generally circularcross-sectional area. However, passages 514, 614 can also have othernon-circular cross-sectional areas, such as square, rectangle, triangle,oval, star, polygon, and irregular shapes. In addition, thecross-sectional area of passages 514, 614 can vary from inner surface208 to outer surface 210. For example, passages 514, 614 can have adecreasing cross-sectional area from inner surface 208 to outer surface210, an increasing cross-section area from inner surface 208 to outersurface 210, a cross-section area that fluctuates between increased anddecreases size, or a cross-sectional area that changes shape as itpasses from inner surface 208 to outer surface 210.

FIGS. 8A-D illustrate a seventh example of a cage 700 that can be usedwith the control valve 10 described above and shown in FIG. 1. Cage 700can also be manufactured using an Additive Manufacturing Technologyprocess described in detail above for cage 100. Cage 700 is similar tocage 200 described above and uses the same reference numbers foridentical parts.

As shown in FIGS. 8A-D, cage 700 generally includes a solid, unitarycircumferential wall 202 forming a hollow central bore 212, within whichthe valve plug 26 will slide to control fluid flow through cage 200.Wall 202 defines a first end 204, an opposing second end 206, an innersurface 208, and an opposing outer surface 210. Passages 714 are formedthrough wall 202 and extend between inner surface 208 and outer surface210. Passages 714 can be used to characterized fluid flowing throughcage 700 by, for example, reducing the pressure of the fluid as it flowsthrough passages 714 or providing a tortured flow path through wall 202to reduce the velocity of the fluid flowing through cage 700.

In the example shown in FIGS. 8A-D, passages 714 follow a non-linear,generally stair-stepped shaped path from inner surface 208 to outersurface 210 of wall 202, which provides a tortured flow path for thefluid passing through cage 700. For example, as can be seen in FIGS.8C-D, passages 714 can extend radially from inner surface 208, turnapproximately 90 degrees and extend generally tangentially, turnapproximately 90 degrees in the opposite direction to extend radially,turn approximately 90 degrees in the same direction to extend generallytangentially, and turn approximately 90 degrees in the oppositedirection to extend radially to outer surface 210. In addition, passages714 in vertically adjacent rows can have stair-stepped shapes that turnin opposite directions. As can be seen in FIG. 8C, passages 714 in thefirst row turn right, left, left, right, while passages 714 in thesecond row (FIG. 8D), vertically adjacent the first row, turn left,right, right, left.

Furthermore, as can be seen in FIGS. 8C-D, the locations of passages 714at outer surface 210 can be angularly offset between vertically adjacentrows so that the exhaust from each vertically adjacent passage does notconverge, which can be used to avoid producing aerodynamic noise.

As described above and shown in FIGS. 8A-D, passages 714 can have agenerally square cross-sectional area. However, passages 714 can alsohave other cross-sectional areas, such as circular, rectangle, triangle,oval, star, polygon, and irregular shapes. In addition, thecross-sectional area of passages 714 can vary from inner surface 208 toouter surface 210. For example, passages 714 can have a decreasingcross-sectional area from inner surface 208 to outer surface 210, anincreasing cross-section area from inner surface 208 to outer surface210, a cross-section area that fluctuates between increased anddecreases size, or a cross-sectional area that changes shape as itpasses from inner surface 208 to outer surface 210. Furthermore, asealed cavity 220, such as a “lightning hole” or “weight saver” ormanifold, can also be formed in wall 202 of cage 700, to reduce theweight of cage 700 and save material, which was not possible usingstandard manufacturing techniques.

FIGS. 9A-C illustrate an eighth example of a cage 800 that can be usedwith the control valve 10 described above and shown in FIG. 1. Cage 800can also be manufactured using an Additive Manufacturing Technologyprocess described in detail above for cage 100. Cage 800 is identical tocage 200 described above and uses the same reference numbers foridentical parts, except for passages 814 formed through wall 202. Incage 800, passages 814 have a cross-sectional area that varies frominner surface 208 to outer surface 210. In the example shown, thecross-sectional area of passages 814 increases from inner surface 208 tothe center of wall 202 and decreases from the center of wall 202 toouter surface 210.

As described above, passages 814 can have a generally circularcross-sectional area. However, passages 814 can also have othernon-circular cross-sectional areas, such as square, rectangle, triangle,oval, star, polygon, and irregular shapes. In addition, thecross-sectional area of passages 814 can vary from inner surface 208 toouter surface 210. For example, passages 814 can have a decreasingcross-sectional area from inner surface 208 to outer surface 210, anincreasing cross-section area from inner surface 208 to outer surface210, a cross-section area that fluctuates between increased anddecreases size, or a cross-sectional area that changes shape as itpasses from inner surface 208 to outer surface 210.

FIG. 10 illustrates a ninth example of a cage 900 that can be used withthe control valve 10 described above and shown in FIG. 1. Cage 900 canalso be manufactured using an Additive Manufacturing Technology processdescribed in detail above for cage 100. Cage 900 is identical to cage200 described above and uses the same reference numbers for identicalparts, except that passages 914 through wall 202 have directionalchanges in the vertical direction as well as the horizontal direction.In the particular example shown, passages 914 are arcuate and follow agenerally helical path through wall 202. Furthermore, the locations ofpassages 914 at outer surface 210 can be angularly offset betweenvertically adjacent rows so that the exhaust from each verticallyadjacent passage does not converge, which can be used to avoid producingaerodynamic noise.

As described above and shown in FIG. 10, passages 914 can have agenerally circular cross-sectional area. However, passages 914 can alsohave other non-circular cross-sectional areas, such as square,rectangle, triangle, oval, star, polygon, and irregular shapes. Inaddition, the cross-sectional area of passages 914 can vary from innersurface 208 to outer surface 210. For example, passages 914 can have adecreasing cross-sectional area from inner surface 208 to outer surface210, an increasing cross-section area from inner surface 208 to outersurface 210, a cross-section area that fluctuates between increased anddecreases size, or a cross-sectional area that changes shape as itpasses from inner surface 208 to outer surface 210.

FIGS. 11A-B illustrate an example cage 1000 that can be used in controlvalves having side to side fluid flow, rather than “flow up” or “flowdown” fluid flow as described above for control valve 10. As shown inFIG. 11B, in control valves using cage 1000, the inlet flow F1 willenter cage 1000 through one side, pass through circumferential wall 1002into central bore 1012 and the outlet flow F2 will exit central bore1012 through the opposite side of cage 1000. Cage 1000 can also bemanufactured using an Additive Manufacturing Technology processdescribed in detail above for cage 100.

Cage 1000 generally includes a solid, unitary circumferential wall 1002forming a hollow central bore 1012, within which the valve plug 26 willslide to control fluid flow through cage 1000. Wall 1002 defines a firstend 1004, an opposing second end 1006, an inner surface 1008, and anopposing outer surface 1010. Passages 1014 are formed through wall 1002and extend between inner surface 1008 and outer surface 1010. Passages1014 can be used to characterized fluid flowing through cage 200 by, forexample, reducing the pressure of the fluid as it flows through passages1014 or providing a tortured flow path through wall 1002 to reduce thevelocity of the fluid flowing through cage 1000.

In the example shown, passages 1014 have both straight portions andarcuate portions and follow a non-linear path from inner surface 1008 toouter surface 1010 of wall 1002 and direct the fluid through cage 1000.In addition, the locations of passages 1014 at outer surface 1010 can beangularly offset between vertically adjacent rows and each row can be“reversed” from adjacent rows so that the exhaust from each verticallyadjacent passage does not converge, which can be used to avoid producingaerodynamic noise.

As described above, passages 1014 can have a generally circularcross-sectional area. However, passages 1014 can also have othernon-circular cross-sectional areas, such as square, rectangle, triangle,oval, star, polygon, and irregular shapes. In addition, thecross-sectional area of passages 1014 can vary from inner surface 1008to outer surface 1010. For example, passages 1014 can have a decreasingcross-sectional area from inner surface 1008 to outer surface 1010, anincreasing cross-section area from inner surface 1008 to outer surface1010, a cross-section area that fluctuates between increased anddecreases size, or a cross-sectional area that changes shape as itpasses from inner surface 1008 to outer surface 1010. Furthermore, asealed cavity 1020, such as a “lightning hole” or “weight saver” ormanifold, can also be formed in wall 1002 of cage 1000, to reduce theweight of cage 1000 and save material, which was not possible usingstandard manufacturing techniques.

While various embodiments have been described above, this disclosure isnot intended to be limited thereto. Variations can be made to thedisclosed embodiments that are still within the scope of the appendedclaims.

What is claimed is:
 1. A control valve, comprising: a body having aninlet and an outlet; a valve seat positioned in a passageway of the bodybetween the inlet and the outlet; a valve plug positioned within thebody and movable between a closed position, in which the valve plugsealingly engages the valve seat, and an open position, in which thevalve plug is spaced away from the valve seat; and a cage disposedwithin the body adjacent the valve seat and proximate the valve plug toprovide guidance for the valve plug, the cage comprising: acircumferential wall having an inner surface and an outer surface; and aplurality of passages formed through the wall and extending between theinner surface and the outer surface; wherein each of the passagescomprises a first portion and a second portion; the first portion of thepassage extends from the inner surface of the wall and has a firstdiameter; and the second portion of the passage extends from the outersurface of the wall and has a second diameter, smaller than the firstdiameter.
 2. The control valve of claim 1, wherein the circumferentialwall of the cage is solid.
 3. The control valve of claim 1, wherein eachof the passages comprises a non-circular cross-sectional area.
 4. Thecontrol valve of claim 3, wherein the cross-sectional area is one of asquare, a rectangle, a triangle, an oval, a stars, a polygon, and anirregular shape.
 5. The control valve of claim 1, further comprising asealed cavity formed in the wall of the cage.
 6. A control valve,comprising: a body having an inlet and an outlet; a valve seatpositioned in a passageway of the body between the inlet and the outlet;a valve plug positioned within the body and movable between a closedposition, in which the valve plug sealingly engages the valve seat, andan open position, in which the valve plug is spaced away from the valveseat; and a cage disposed within the body adjacent the valve seat andproximate the valve plug to provide guidance for the valve plug, thecage comprising: a solid, unitary circumferential wall having an innersurface and an outer surface; and a plurality of passages formed throughthe wall and extending between the inner surface and the outer surface;wherein each of the passages follows a non-linear path from the innersurface to the outer surface.
 7. The control valve of claim 6, whereinthe non-linear path is one of an arcuate path, a helical path, and astair-stepped shaped path.
 8. The control valve of claim 6, wherein eachof the passages comprises a non-circular cross-sectional area.
 9. Thecontrol valve of claim 8, wherein the cross-sectional area is one of asquare, a rectangle, a triangle, an oval, a stars, a polygon, and anirregular shape.
 10. The control valve of claim 6, further comprising asealed cavity formed in the wall of the cage.
 11. The control valve ofclaim 6, wherein each of the passages comprises a cross-sectional areathat varies from the inner surface to the outer surface.
 12. A controlvalve, comprising: a body having an inlet and an outlet; a valve seatpositioned in a passageway of the body between the inlet and the outlet;a valve plug positioned within the body and movable between a closedposition, in which the valve plug sealingly engages the valve seat, andan open position, in which the valve plug is spaced away from the valveseat; and a cage disposed within the body adjacent the valve seat andproximate the valve plug to provide guidance for the valve plug, thecage comprising: a solid, unitary circumferential wall having an innersurface and an outer surface; and a plurality of passages formed throughthe wall and extending between the inner surface and the outer surface;wherein each of the passages comprises a cross-sectional area thatvaries in size from the inner surface to the outer surface.
 13. Thecontrol valve of claim 12, wherein each of the passages comprises anon-circular cross-sectional area.
 14. The control valve of claim 13,wherein the cross-sectional area is one of a square, a rectangle, atriangle, an oval, a stars, a polygon, and an irregular shape.
 15. Thecontrol valve of claim 12, further comprising a sealed cavity formed inthe wall of the cage.
 16. A cage for a control valve, the cagecomprising: a circumferential wall having an inner surface and an outersurface; and a plurality of passages formed radially through the wallfrom the inner surface to the outer surface; wherein each of thepassages comprises a first portion and a second portion; the firstportion of the passage extends from the inner surface of the wall andhas a first diameter; and the second portion of the passage extends fromthe outer surface of the wall and has a second diameter, smaller thanthe first diameter.
 17. The cage of claim 16, wherein thecircumferential wall is solid.
 18. The cage of claim 16, wherein each ofthe passages comprises a non-circular cross-sectional area.
 19. The cageof claim 18, wherein the cross-sectional area is one of a square, arectangle, a triangle, an oval, a stars, a polygon, and an irregularshape.
 20. The cage of claim 16, further comprising a sealed cavityformed in the wall of the cage.
 21. A cage for a control valve, the cagecomprising: a solid, unitary circumferential wall having an innersurface and an outer surface; and a plurality of passages formed throughthe wall and extending between the inner surface and the outer surface;wherein each of the passages follows a non-linear path from the innersurface to the outer surface.
 22. The cage of claim 21, wherein thenon-linear path is one of an arcuate path, a helical path, and astair-stepped shaped path.
 23. The cage of claim 21, wherein each of thepassages comprises a non-circular cross-sectional area.
 24. The cage ofclaim 23, wherein the cross-sectional area is one of a square, arectangle, a triangle, an oval, a stars, a polygon, and an irregularshape.
 25. The cage of claim 21, further comprising a sealed cavityformed in the wall of the cage.
 26. The cage of claim 21, wherein eachof the passages comprises a cross-sectional area that varies from theinner surface to the outer surface.
 27. A cage for a control valve, thecage comprising: a solid, unitary circumferential wall having an innersurface and an outer surface; and a plurality of passages formed throughthe wall and extending between the inner surface and the outer surface;wherein each of the passages comprises a cross-sectional area thatvaries in size from the inner surface to the outer surface.
 28. The cageof claim 27, wherein each of the passages comprises a non-circularcross-sectional area.
 29. The cage of claim 28, wherein thecross-sectional area is one of a square, a rectangle, a triangle, anoval, a stars, a polygon, and an irregular shape.
 30. The cage of claim27, further comprising a sealed cavity formed in the wall of the cage.